Sanding device and method

ABSTRACT

A sanding device and associated methods are shown. Sanding devices shown include attached lighting devices and marking devices. In use, lighting devices attached to the sanding devices may be used to cast shadows on imperfections in a surface such as a wall. The marking devices may be optionally used to mark the imperfections for later attention.

CLAIM FOR PRIORITY

This application claims the benefit of priority of U.S. Provisional Patent Application Ser. No. 62/213,832, filed Sep. 3, 2015.

TECHNICAL FIELD

Embodiments described herein generally relate to sanding. Specific examples may include drywall construction, and repair. Specific examples may include tools and methods for working on mud regions in drywall, such as seams between drywall panels.

BACKGROUND

Any number of surfaces may require sanding to provide a smooth, finished surface. One example includes drywall construction in residential or commercial settings. Although the present invention uses drywall work as an example to illustrate various advantages, the invention is not so limited. Other sanding settings such as woodwork exterior painting, etc. may benefit from examples of the present invention.

When sanding a surface, it may be difficult for the naked eye to visualize imperfections. Additionally, once identified, it may be inconvenient to address the imperfections right away once they are identified. These and other problems are addressed by devices and methods disclosed in the following description.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a sanding device in accordance with some embodiments of the invention.

FIG. 2 is another sanding device in accordance with some embodiments of the invention.

FIG. 3 is another sanding device in accordance with some embodiments of the invention.

FIG. 4 is another sanding device in accordance with some embodiments of the invention.

FIG. 5 is another sanding device in accordance with some embodiments of the invention.

FIG. 6 is another sanding device in accordance with some embodiments of the invention.

FIG. 7 is another sanding device in accordance with some embodiments of the invention.

FIG. 8 is a flow diagram of a method of working a drywall surface in accordance with some embodiments of the invention.

DESCRIPTION OF EMBODIMENTS

The following description and the drawings sufficiently illustrate specific embodiments to enable those skilled in the art to practice them. Other embodiments may incorporate structural, logical, electrical, process, and other changes. Portions and features of some embodiments may be included in, or substituted for, those of other embodiments. Embodiments set forth in the claims encompass all available equivalents of those claims.

FIG. 1 shows a sanding device 100 according to one example of the invention. The sanding device 100 includes a sanding body 101, having at least one planar surface 106. A single planar surface 106 may be used, or multiple planar surfaces may be available, such as in the example of FIG. 1. In one example one of the surfaces includes an angled surface 108 to permit better visibility of the surface being sanded, and to permit access to tight corners during a sanding operation.

In one example, one or more surfaces such as the planar surface 106 are impregnated with an abrasive material for sanding, or otherwise having an abrasive material adhered to a surface. In another example, sandpaper may be removably wrapped around the sanding device 100 and the sanding device 100 provides a form to hold. In such an example, the sandpaper may be discarded and replaced with fresh sandpaper as needed.

In one example the material of the sanding body 101 includes a resilient material to better conform to a surface being sanded. Examples of a resilient material include rubber or plastic. In selected examples, an open cell structure such as sponge may be used. In other examples, a closed cell foam material may be used. In selected examples a rigid material may be used, such as a hard plastic, wood, or other material.

In one example, the sanding body 101 includes a first half 102 and a second half 104, although the invention is not so limited. One advantage of forming the sanding body 101 as a first half 102 and a second half 104 includes the ability to house additional components more easily within the sanding body 101. Examples of additional components are discussed in more detail below.

In one example, the first half 102 and second half 104 are coupled together using one or more fasteners, or an adhesive. Although two halves are used as an example, one of ordinary skill in the art, having the benefit of the present disclosure, will recognize that other numbers of components assembled to form a sanding body are also within the scope of the invention.

In one example, the sanding device 100 includes one or more light sources. In the example of FIG. 1, a first light source 110, and second light source 112, and a third light source 114 are shown. In other examples, only a single light source may be included. The locations shows for the first light source 110, second light source 112, a third light source 114 are possible locations for a single light source. In one example, one or more light sources includes an LED light source. An advantage of LED lighting includes low power consumption, and high brightness. Although an LED light source is used as an example, other forms of light source, such as incandescent, laser, plasma, etc. are also within the scope of the invention.

A light source can be used to cast and shadow across a surface being sanded. The shadow from the light source will make visible an imperfection that may be difficult or impossible for a worker to see without the aid of the light source. It is advantageous to locate the light source near to the surface being sanded, where it will shine a beam substantially parallel to the surface. In such a location, shadows from small imperfections in the surface are more easily seen.

In one example, the sanding device 100 includes one or more integrated marking devices 120. When sanding a surface, such as a drywall surface during residential or commercial construction, imperfections may become apparent that will require filling with drywall compound to fix the imperfection. When a worker is engaged in a sanding operation, it is less efficient to stop the sanding operation for every imperfection requiring filling with drywall compound. In one example of the present invention, the marking device 120 may be used to mark a location of an imperfection requiring filling. In this way, a sanding operation can be completed on a wall surface, and the worker can return later to fill all marked imperfections that require filling, in contrast to sanding.

It is advantageous to have a marking device 120 integrated within the sanding device 100, because when imperfections requiring filling are discovered, the worker does not need to stop to find a pencil or chalk, etc. The sanding device 100 with integrated marking device 120 will always be in the worker's hand. In contrast, a separate pencil, chalk, etc. may be accidentally set down somewhere at a jobsite and forgotten causing lost time, and likely frustration, to re-locate it.

In one example, the integrated marking device 120 is located on a side surface of the sanding device 100, although the invention is not so limited. A side surface may be more readily accessible to a worker, and cause minimal interference with normal sanding operations.

In one example a power switch 122 for the light source also protrudes through a side surface of the sanding device 100. In other examples, the power switch may be internal to the sanding device 100, and actuation of the power switch may be accomplished by squeezing a deformable portion of the sanding device 100 to cause the switch to actuate.

FIG. 2 shows internal components of a sanding device 200 according to an example of the invention. Components of sanding device 200 may be similar to sanding device 100 shown in FIG. 1. The sanding device 200 includes the first half 102 and the second half 104. The first half 102 includes the at least one planar surface 106.

A marking device 220 is shown. In the example of FIG. 2, the marking device 220 includes a marking material 222, such as chalk, pencil lead, crayon or other wax, etc. In one example the marking material 222 is retractable, and may be housed substantially within the sanding body 101 in a retracted state, or extended as shown in FIG. 2, to use for marking a region as described in examples above. In one example, the act of retracting or extending the marking material from within the marking device, also serves as an actuation switch for a lighting device.

In the example of FIG. 2, a pair of lighting devices 204, 206 are shown, although a single lighting device option is also within the scope of the invention. One or more batteries 202 are coupled to the lighting devices 204, 206 with wiring 208.

In the example of FIG. 2, a number of cavities 203 are shown within at least the first half 102, and optionally within both the first half 102 and the second half 104, to accommodate the components such as the lighting devices 204, 206, batteries 202, marking device 220, etc. In one example, the first half 102 and the second half 104 of the sanding body 101 are permanently assembled around the components. In another example, the first half 102 and the second half 104 may be separated to replace one or more components as needed, such as for example, the batteries 202.

FIG. 3 shows another example of a sanding device 300 according to an example of the invention. The sanding device 300 includes a sanding body 301 having at least one planar surface 306. A lighting device 310 is shown removably coupled to the sanding body 301. In the example of FIG. 3, one or more pins 312 are included on the lighting device 310. In one example, a number of ridges 314 are included on the one or more pins 312 to increase friction and better hold the lighting device 310 on the sanding body 301. In one example, the sanding body 301 includes a porous material such as an open celled sponge, or a closed cell foam. The one or more pins 312 may be inserted into the sanding body 301 to hold the lighting device 310 in place. In the example of FIG. 3, a recess 320 is included within the sanding body 301, and shaped to hold the lighting device 310 securely within the recess 320.

FIG. 4 shows another example of a sanding device 400 according to an example of the invention. The sanding device 400 includes a sanding body 401 having at least one planar surface 406. A lighting device 310 is shown removably coupled to the sanding body 401. In the example of FIG. 4, one or more pins 412 are included on the lighting device 410. In one example, a number of bayonet fasteners 414 are included on the one or more pins 412 to better hold the lighting device 410 on the sanding body 401. A side surface 402 where the lighting device 410 may be attached is shown in FIG. 4 without a recess as in the example of FIG. 3.

One of ordinary skill in the art, having the benefit of the present disclosure, will recognize that individual features including, but not limited to, bayonet fittings 414 and recesses 320 may be mixed, used or omitted as desired between the Figures that illustrate various non-limiting examples.

FIG. 5 shows yet another example of a sanding device 500 according to an example of the invention. The sanding device 500 includes a sanding body 501 having at least one planar surface 506. A lighting device 510 is shown removably coupled to the sanding body 501. In the example of FIG. 5, a recess 520 is shown, and used to attach the lighting device 510 to the sanding body 501 without the use of pins or other fasteners. In the example of FIG. 5, the recess 520 is close fitting about the lighting device 510, and friction holds the lighting device 510 in place within the sanding body 501.

FIG. 6 shows another example of a sanding device 600 according to an example of the invention. The sanding device 600 includes a sanding body 601 having at least one planar surface 606. The sanding body 601 of sanding device 600 is integrally formed as a single piece, and does not include a first half or second half component as shown in FIGS. 1 and 2. In the example of FIG. 6, a lighting device 610 and a marking device 630 are attached to the sanding body 601 in corresponding cavities 620 and 640. Similar to the example described above, in the example of FIG. 6, friction may hold components such as the lighting device 610 and marking device 630 within cavities 620 and 640. In one particular example where the sanding body 601 is formed from a resilient material, the cavities 620 and 640 are more easily deformed to accommodate the lighting device 610 and marking device 630, and the resilient nature of the material provides an improved holding force to keep the components in place within the sanding body 601.

FIG. 7 shows internal components of a sanding device 700 according to an example of the invention. The sanding device 700 includes a first half 702 and the second half 704. The first half 702 includes the at least one planar surface 706.

A marking device 720 is shown. In the example of FIG. 7, the marking device 720 includes a marking material 722, such as chalk, pencil lead, crayon or other wax, etc. In one example the marking material 722 is retractable, and may be housed substantially within the sanding body in a retracted state, or extended as shown in FIG. 7, to use for marking a region as described in examples above. In one example, the act of retracting or extending the marking material from within the marking device, also serves as an actuation switch for a lighting device.

In the example of FIG. 7, a pair of lighting devices 712, 714 are shown, although a single lighting device option is also within the scope of the invention. One or more batteries 710 are coupled to the lighting devices 712, 714 with wiring 716. In the example of FIG. 7, a charging port 730 is further included to charge batteries 710 as needed. This option removes the need in other examples to either replace batteries, or discard the sanding device when the batteries die.

FIG. 8 shows an example method of using a sanding device according to one embodiment of the invention. In operation 802, a drywall surface is sanded using a sanding body. In operation 804, a flatness of the drywall surface is checked using a light source attached to the sanding body to cast a shadow on an imperfection in the drywall surface. In operation 806, the imperfection is marked using an integrated marking device attached to the sanding body.

To better illustrate the method and apparatuses disclosed herein, a non-limiting list of examples is provided here:

Example 1 includes a sanding device, including a sanding body, including at least one planar surface, a light source attached to the sanding body and located above the at least one planar surface, and an integrated marking device attached to the sanding body.

Example 2 includes the sanding device of example 1, wherein the light source is an LED light source.

Example 3 includes the sanding device of any one of examples 1-2, wherein the integrated marking device is optionally retractable within the sanding body.

Example 4 includes the sanding device of any one of examples 1-3, wherein the integrated marking device includes a graphite marking material.

Example 5 includes the sanding device of any one of examples 1-4, wherein the integrated marking device includes a chalk marking material.

Example 6 includes the sanding device of any one of examples 1-5, wherein the light source is detachable from the sanding body.

Example 7 includes the sanding device of any one of examples 1-6, further including a charging port for a light source battery.

Example 8 includes the sanding device of any one of examples 1-7, wherein the integrated marking device also functions as an on/off switch for the light source.

Example 9 includes the sanding device of any one of examples 1-8, wherein the sanding body includes a recess that houses the light source.

Example 10 includes the sanding device of any one of examples 1-9, wherein the recess is a hole within an interior of the sanding body.

Example 11 includes the sanding device of any one of examples 1-10, wherein the recess is a trench in a side of the sanding body.

Example 12 includes a sanding device, including a sanding sponge body, including at least one planar surface, a light source, and at least one attachment pin coupled to the light source to penetrate the sanding sponge body and removably attach the light source to the sanding sponge body.

Example 13 includes the sanding device of claim 12, further including an integrated marking device attached to the sanding sponge body.

Example 14 includes the sanding device of any one of examples 12-13, wherein the attachment pin includes at least one bayonet fitting.

Example 15 includes the sanding device of any one of examples 12-14, wherein the sanding sponge body includes a recess that houses the light source.

Example 16 includes the sanding device of any one of examples 12-15, wherein the recess is a hole within an interior of the sanding sponge body.

Example 17 includes the sanding device of any one of examples 12-16, wherein the recess is a trench in a side of the sanding sponge body.

Example 18 includes a method including sanding a drywall surface using a sanding body, checking a flatness of the drywall surface using a light source attached to the sanding body to cast a shadow on an imperfection in the drywall surface, and marking the imperfection using an integrated marking device attached to the sanding body.

Example 19 includes the method of example 18, further including extending a retractable marking device from within the sanding body, marking the imperfection, and retracting the marking device back within the sanding body.

Example 20 includes the method of any one of examples 18-19, further including detaching the light source from the sanding body when a battery replacement is needed and re-attaching the light source once the battery has been replaced.

The above detailed description includes references to the accompanying drawings, which form a part of the detailed description. The drawings show, by way of illustration, specific embodiments in which the invention can be practiced. These embodiments are also referred to herein as “examples.” Such examples can include elements in addition to those shown or described.

However, the present inventors also contemplate examples in which only those elements shown or described are provided. Moreover, the present inventors also contemplate examples using any combination or permutation of those elements shown or described (or one or more aspects thereof), either with respect to a particular example (or one or more aspects thereof), or with respect to other examples (or one or more aspects thereof) shown or described herein.

In this document, the terms “a” or “an” are used, as is common in patent documents, to include one or more than one, independent of any other instances or usages of “at least one” or “one or more.” In this document, the term “or” is used to refer to a nonexclusive or, such that “A or B” includes “A but not B,” “B but not A,” and “A and B,” unless otherwise indicated. In this document, the terms “including” and “in which” are used as the plain-English equivalents of the respective terms “comprising” and “wherein.” Also, in the following claims, the terms “including” and “comprising” are open-ended, that is, a system, device, article, composition, formulation, or process that includes elements in addition to those listed after such a term in a claim are still deemed to fall within the scope of that claim. Moreover, in the following claims, the terms “first,” “second,” and “third,” etc. are used merely as labels, and are not intended to impose numerical requirements on their objects.

The above description is intended to be illustrative, and not restrictive. For example, the above-described examples (or one or more aspects thereof) may be used in combination with each other. Other embodiments can be used, such as by one of ordinary skill in the art upon reviewing the above description. The Abstract is provided to comply with 37 C.F.R. §1.72(b), to allow the reader to quickly ascertain the nature of the technical disclosure. It is submitted with the understanding that it will not be used to interpret or limit the scope or meaning of the claims. Also, in the above Detailed Description, various features may be grouped together to streamline the disclosure. This should not be interpreted as intending that an unclaimed disclosed feature is essential to any claim. Rather, inventive subject matter may lie in less than all features of a particular disclosed embodiment. Thus, the following claims are hereby incorporated into the Detailed Description, with each claim standing on its own as a separate embodiment, and it is contemplated that such embodiments can be combined with each other in various combinations or permutations. The scope of the invention should be determined with reference to the appended claims, along with the full scope of equivalents to which such claims are entitled. 

1. A sanding device, comprising: a sanding body, including at least one planar surface; a light source attached to the sanding body and located above the at least one planar surface; and an integrated marking device attached to the sanding body.
 2. The sanding device of claim 1, wherein the light source is an LED light source.
 3. The sanding device of claim 1, wherein the integrated marking device is optionally retractable within the sanding body.
 4. The sanding device of claim 1, wherein the integrated marking device includes a graphite marking material.
 5. The sanding device of claim 1, wherein the integrated marking device includes a chalk marking material.
 6. The sanding device of claim 1, wherein the light source is detachable from the sanding body.
 7. The sanding device of claim 1, further including a charging port for a light source battery.
 8. The sanding device of claim 1, wherein the integrated marking device also functions as an on/off switch for the light source.
 9. The sanding device of claim 1, wherein the sanding body includes a recess that houses the light source.
 10. The sanding device of claim 9, wherein the recess is a hole within an interior of the sanding body.
 11. The sanding device of claim 9, wherein the recess is a trench in a side of the sanding body.
 12. A sanding device, comprising: a sanding sponge body, including at least one planar surface; a light source; and at least one attachment pin coupled to the light source to penetrate the sanding sponge body and removably attach the light source to the sanding sponge body.
 13. The sanding device of claim 12, further including an integrated marking device attached to the sanding sponge body.
 14. The sanding device of claim 12, wherein the attachment pin includes at least one bayonet fitting.
 15. The sanding device of claim 12, wherein the sanding sponge body includes a recess that houses the light source.
 16. The sanding device of claim 15, wherein the recess is a hole within an interior of the sanding sponge body.
 17. The sanding device of claim 15, wherein the recess is a trench in a side of the sanding sponge body.
 18. A method, comprising: sanding a drywall surface using a sanding body; checking a flatness of the drywall surface using a light source attached to the sanding body to cast a shadow on an imperfection in the drywall surface; and marking the imperfection using an integrated marking device attached to the sanding body.
 19. The method of claim 18, further including: extending a retractable marking device from within the sanding body; marking the imperfection; and retracting the marking device back within the sanding body.
 20. The method of claim 18, further including detaching the light source from the sanding body when a battery replacement is needed and re-attaching the light source once the battery has been replaced. 